Taking-up method and apparatus for automatic winder

Abstract: An automatic winder wherein a yarn (Y) is taken up from a yarn supply bobbin (24) onto a package (25) and a defect of the yarn (Y) is detected and then the yarn (Y) is cut and jointed comprises taking up stopping means for stopping taking up when the number of times of detection of a defect becomes higher than a fixed number for a fixed length, and taking up re-starting means for releasing and abandoning the yarn (Y) of the yarn supply bobbin (24) for a predetermined time after such stopping, joining the remaining yarn (Y) on the yarn supply bobbin (24) and re-starting taking up.

Description: BACKGROUND OF THE INVENTION Field of the Invention This invention relates to an automatic winder which winds up a yarn of a fixed length on a take-up package while keeping the quality, and particularly to an automatic winder which can restore itself without manual operation even when a defect of a yarn occurs frequently. Prior Art An automatic winder (DE-A-3 80 61 65) is an apparatus which is constituted from a large number of take-up units each of which takes up a yarn of a yarn supply bobbin supplied thereto from a spinning frame onto a package joining the yarn so that the yarn on the take-up package may have a predetermined length. If the yarn supply bobbin becomes empty, then it is automatically replaced with a new yarn supply bobbin, and a yarn supplied from the new yarn supply bobbin can be connected to the yarn already taken up on the take-up package to continue taking up. Meanwhile, when the yarn is broken during taking up, or when a defect of the yarn is detected and the yarn is cut, the thus broken yarn or a yarn of a succeeding conforming article is connected to the yarn on the take-up package side to continue taking up. Detection and cutting of a defect of a yarn are performed by a slub catcher. The slub catcher is located on a passage of the yarn and always checks the thickness of the yarn. When abnormality in thickness that the yarn is thicker or thinner than a certain ratio compared with the original thickness or abnormality that some variation in thickness continues over a predetermined length is detected, the yarn is cut compulsorily. After such compulsory cutting of the yarn joining of the yarn is performed by means of a yarn joining apparatus. Since the opposite ends of the yarn thus cut are lost by some lengths upon joining of the yarn, the defective portion is roughly removed at the front and the rear of the defective portion. Then, taking up is continued. A take-up package can be put into a condition free from any defective portion in this manner. The series of operations of the detecting operation of a defect, the cutting operation and the yarn joining operation described above is called yarn joining cycle. When such yarn joining cycle occurs singly, it is possible to remove the defective portion and continue taking up as described above. However, when such yarn joining cycle occurs frequently, it is considered that the yarn supply bobbin or some other element has some trouble, and accordingly, processing of an operator is waited for without continuing taking up. In particular, when the number of times of a yarn joining cycle for a fixed length is higher than a predetermined number, the automatic winder develops an alarm and stops the take-up unit. The take-up unit thus waits for an operator. In other words, the stopping condition continues unless taking up is re-started by way of operation of a switch or the like after an operator performs its processing. When the alarm is developed, although an operator may sometimes discover a trouble or the like of the machine and repair the machine, frequent occurrence of the yarn joining cycle is eliminated in most cases only by replacing the yarn supply bobbin. In other words, taking up is re-started only by such simple processes as abandoning of the yarn supply bobbin having a remaining yarn, mounting of a new yarn supply bobbin and depression of the switch for re-starting of operation. However, in a factory or equipment which includes an automatic winder, normally a large number of automatic winders are juxtaposed in a wide site, and one automatic winder is composed of a large number of take-up units. Besides, operation of such automatic winder is almost automated, and the inside of the factory is almost in a man-free condition. An operator watches a monitor of a concentrated control apparatus in a control room or a like place and perceives occurrence of such an alarm as described above. Accordingly, for a time after a take-up unit stops actually until processing is performed, the time for the concentrated control apparatus to collect information of the take-up unit, the time for the operator to recognize the display of the monitor and the time for the operator to go to the spot are involved. Those times make a stopping time of the spindle. Meanwhile, since only such simple processing as described above is required in most cases, it is cumbersome for the operator to go to the trouble of going to the spot rapidly in the wide factory. SUMMARY OF THE INVENTION It is an object of the present invention to provide an automatic winder which can, solving the subject described above, restore itself without manual operation even when a defect of a yarn appears frequently. This object is attained by the method and the automatic winder as defined in claim 1 and 9, resp. Therefore, with an automatic winder a yarn is taken up from a yarn supply bobbin onto a package and a defect of the yarn is detected and then the yarn is cut and joined comprises taking up stopping means for stopping taking up when the number of times of detection of a defect within a predetermined amount of the yarn by such detection exceeds a preset number of times, and taking up re-starting means for releasing and abandoning the yarn of the yarn supply bobbin for a predetermined time after such stopping, joining the remaining yarn on the yarn supply bobbin and re-starting taking up. While the cause by which a defect of a yarn occurs frequently may be a trouble of a spinning frame, a mechanical trouble or a trouble of a raw material at a preceding stage or some other cause, it is experientially known that the cause can be eliminated if a yarn supply bobbin is replaced as described above. However, all of remaining yarns abandoned may not be non-conforming articles. Acutally, it has been found out that, when it was attempted to artificially release, upon development of the alarm described above, a remaining yarn on a yarn supply bobbin over some length and then perform yarn joining and re-start taking up, it was in most cases possible to continue taking up without any trouble. In other words, if a yarn of some length is abandoned from a portion at which a yarn break occurs frequently, then it seldom occurs that a yarn break thereafter takes place frequently. If such processing can be performed without manual operation, there is no necessity for an operator to go to the site any more. In particular, with the construction described above, when the number of times of detection of a defect becomes higher than the predetermined number for the fixed length, taking up is stopped, and the yarn of the yarn supply bobbin is released and abandoned for the predetermined time. Here, the predetermined time is a time for which a yarn of such a length which prevents re-occurrence of a yarn break is released. Thereafter, the remaining yarn on the yarn supply bobbin and the yarn on the take-up package side are joined with each other, and taking up is re-started. It is to be noted that, when a yarn break occurs again within the predetermined time after taking up is re-started, an alarm is developed and the take-up unit is stopped to wait for an operator. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a block diagram showing an embodiment of the present invention. Fig. 2 is a side elevational view of a take-up unit. Fig. 3 is a front elevational view of the take-up unit. Fig. 4 is a perspective view showing the arrangement of a yarn trap and a tensor. Fig. 5 is a side elevational view, partly in section, illustrating opening and closing conditions of a cover of the yarn trap. Fig. 6 is a time chart of a method of the present invention. Fig. 7 is a side elevational view, partly in section, illustrating a condition wherein the cover is closed when a yarn is sucked by the yarn trap. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT In the following, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. First, an automatic winder will be described. The automatic winder includes a large number of take-up units 21 shown in Figs. 2 and 3 arranged in a juxtaposed relationship with each other. Each of the take-up units 21 can individually perform such operations as yarn releasing, feeding, taking up, yarn joining and removal of a defective yarn. The take-up unit 21 forms a yarn passage Y along which a yarn is fed from a yarn supply bobbin 24, which is placed on and transported by a peg 23 on a bobbin supplying apparatus 22, to a take-up package 25 mounted at an upper portion of the take-up unit 21, and is equipped intermediately of the yarn passage Y with several members having various functions. The names and functions of the members are a tensor 27 for applying suitable tension to a yarn released from the yarn supply bobbin 24 and fed by way of a guide 26, a slub catcher 28 which detects an irregular portion of a yarn and cuts the yarn and also serves for detection of travel of a yarn, a yarn joining apparatus 29 for joining yarns on the yarn supply bobbin side and the take-up package side, a first suction arm 30 for guiding a yarn on the yarn supply side to the yarn joining apparatus 29 (in Figs. 2 and 3, it is also shown that the suction arm 30 has moved to the yarn supply bobbin side), a second suction arm 31 for guiding a yarn on the take-up package side to the yarn joining apparatus 29, and a winding drum 32 for rotating the take-up package. The take-up package 25 is removably mounted on the winding drum 32. Meanwhile, a suction pipe 33 is connected to the take-up unit 21 so that air flows for sucking a yarn can be supplied to the suction arms 30 and 31. The take-up unit 21 is mounted uprightly on the automatic winder with a lower end portion thereof supported on a support pipe 34 so that it can be tilted around the support pipe 34. Referring to Fig. 3, above the tensor 27 described above, a yarn trap T which serves as sucking means according to the present embodiment is provided. The yarn trap T is constituted from an air sucking pipe 5 for removing fly waste such as waste thread or waste fiber included in a travelling yarn Y and sucking and holding an end of a yarn broken during taking up, a shutter 15 for opening and closing an inlet opening 5a of the air sucking pipe 5, and a high friction face 15c formed on the surface of the shutter 15 by knurling. The air sucking pipe 5 described above is provided at a position below a yarn guide plate 13 on the yarn passage of the yarn Y to be taken up from the yarn supply bobbin 24 onto the take-up package 25 as shown in Fig. 4 and is connected to an air sucking blower (not shown). A V-shaped guide groove 14 is formed on the yarn guide plate 13, and the yarn Y travels in the interior of the guide groove 14. The inlet opening 5a of the air sucking pipe 5 is opened and closed freely by the shutter 15. The shutter 15 is constituted from a lid plate 15a curved arcuately for substantially opening and closing the inlet opening 5a, the high friction face 15c formed on the surface of the lid plate 15a by knurling, and a bracket 15b connected to an end face of the lid plate 15a. In particular, the high friction face 15c described above is constituted from a plurality of grooves formed on the surface of the lid plate 15a in such a manner as to cross obliquely each other. Meanwhile, the bracket 15b is pivoted by energization of a rotary solenoid 16 provided in a side frame 12, and by such pivotal motion, the lid plate 15a opens or closes the inlet opening 5a of the air sucking pipe 5 as shown in Fig. 5. Here, the rotary solenoid 16 described above has a spring member provided in the inside thereof so that, when it is not energized, the lid plate 15a may be returned to its opening position. It is to be noted that an air actuator or some other member may be used in place of the rotary solenoid 16. Referring to Fig. 2, reference numeral 35 denotes a cutter. The cutter 35 cuts, when the suction arm 30 is pivoted to suck and grasp the yarn extending between the air sucking pipe 5 of the yarn trap T and the yarn supply bobbin 24, the yarn between the suction arm 30 and the yarn trap T to allow the suction arm 30 to suck an end of the yarn on the yarn supply bobbin side. The cut end of the yarn between the cutter 35 and the yarn trap T is sucked into and abandoned by the yarn trap T. Fig. 1 shows a block diagram according to the present invention which is part of a control block of an automatic winder. A slub catcher 28, a tensor 27 and a yarn joining apparatus 29 are such as those described above with reference to Fig. 2. Referring to Fig. 1, an event memory 1 stores occurrence of a yarn break by the slub catcher 28 together with a time indicated by a timer 2, and when the stored time becomes a fixed time with respect to the time indicated by the timer 2, the storage is erased. On the other hand, when the number of events stored exceeds a number of times set in a time number setting section 3, a signal for stopping taking up is generated. In other words, the event memory 1 constitutes taking up stopping means 10 for stopping taking up when the number of times of detection of a defect becomes greater than a predetermined number for a fixed length. A release timer 4 performs opening and closing of the tensor 27, control of the sucking section 5 and instruction of yarn joining to the yarn joining apparatus 29. A release time setting section 6 sets an operation time of the release timer 4. Here, the sucking section 5 signifies a yarn trap T which sucks and discharges a yarn by means of a suction air flow, and is constituted from a member of the sucking section, a pipe (36 in Fig. 2), the suction pipe 33 and some other members. When the sucking section 5 is rendered operative in an open condition of the tensor 27, the yarn supply bobbin can be released. The release timer 4 constitutes taking up re-starting means 11 for joining the remaining yarn of the yarn supply bobbin and re-starting taking up after the yarn of the yarn supply bobbin is released and abandoned for a predetermined time after stopping. A re-starting timer 7 is started upon re-starting after operation of the release timer 4 and performs compulsory stopping if a yarn break is detected by the slub catcher 28 within a time set in a re-starting time setting section 8. Subsequently, operation of the embodiment will be described. The yarn delivered from the yarn supply bobbin 24 is guided along the yarn passage Y by the guide 26 and acted upon by suitable tension by the tensor 27, and then, an irregular portion of the yarn is detected by the slub catcher 28, whereafter the yarn is taken up onto the take-up package 25 by the winding drum 32. If the yarn supply bobbin 24 becomes empty, then the bobbin supplying apparatus 22 replaces the yarn supply bobbin 24 with another new yarn supply bobbin 24. A yarn supplied from the new yarn supply bobbin 24 is sucked at a leading end thereof by the suction arm 30 in the proximity of the guide 26, and is guided to the yarn joining apparatus 29 by a swinging up movement of the suction arm 30. Meanwhile, the yarn taken up already on the take-up package is sucked at a trailing end thereof by the suction arm 31 thus swung up, and is guided into the yarn joining apparatus 29 by a swinging down movement of the suction arm 31. In the yarn joining apparatus 29, the upper and lower yarns are twisted together or joined with each other so that they are connected integrally with each other. Thereafter, taking up can be continued. If the take-up package 25 becomes full, travel of the yarn is stopped and a new take-up package 25 is mounted. As shown in Fig. 1, when an irregular portion of the yarn is detected by the slub catcher 28, cutting, yarn joining and re-starting of taking up are performed. Simultaneously, occurrence of the yarn break and the time of the occurrence are stored into the event memory 1. The stored contents are erased after a predetermined time elapses. Accordingly, only an event or events within the last predetermined time remain in the event memory 1. When the number of events exceeds the number of times set in the time number setting section 3, a signal to stop taking up (P1) is generated. The take-up unit 21 stops its taking up (P2) (see Fig. 6). The release timer 4 opens the tensor 27. After the tensor 27 is opened (P3), the yarn of the yarn supply bobbin 24 is free. When the yarn trap T is released (P4) and the sucking section 5 sucks the yarn, the yarn of the yarn supply bobbin 24 is released. The tensor 27 is closed (P5) when the predetermined time set in the release time setting section 6, for example, 10 seconds, elapses. In the meantime, the yarn of the predetermined length released from the yarn supply bobbin 24 is sucked into the sucking section 5. Further, the cover 15 of the yarn trap T is closed (P6). Subsequently, the yarn joining apparatus 29 performs yarn joining (P7). Thereupon, the yarn on the sucking section 5 side is cut by the cutter 35 described above and is discharged by way of the suction pipe 33, and yarn joining is performed. Then, taking up is re-started (P8) and the re-starting timer 7 is started. Here, in almost all cases, taking up can be continued without suffering from a yarn break. It is to be noted that, while the yarn is sucked into the discharged by the yarn trap T, the cover 15a of the yarn trap T is controlled so that opening and closing thereof are repeated as shown in Fig. 6. When it sometimes occurs that the yarn to be sucked is caught by an end face of the suction pipe 5 at the entrance of the suction pipe 5 so that suction of the yarn is obstructed, the cover 15 is closed to its position of Fig. 7 so that the yarn passage is varied by the cover 15, and consequently, such catching of the yarn by the pipe 5 is eliminated. When a yarn break occurs again immediately after taking up is re-started, it is considered that this may possibly be caused by a trouble of the machine or the like. If the slub catcher 28 operates before the re-starting timer 7 exceeds the time set in the re-starting time setting section 8, the take-up unit 21 develops an alarm and stops itself to wait for an operator. Subsequently, another embodiment will be described. While, in the embodiment described above, a time at which a yarn break occurs is stored into the event memory and the storage is erased after the fixed time, occurrences of a yarn break may be counted within a predetermined taken up length of a yarn. In this instance, since a taken up length of the yarn is detected from rotation of the winding drum 32, the event memory stores such length upon occurrence of a yarn break and erases the storage if the fixed length is thereafter taken up. Further, erasure of the event memory 1 is performed also when the yarn supply bobbin 24 becomes empty and is replaced. In the embodiment mentioned above, the case in which the sucking and discharging action for a yarn is performed by means of the yarn trap T is disclosed. However, it is to be noted that other suction device can be additionally provided, or the first suction arm 30 can suck and discharge a yarn as in the case illustrated in the above embodiment. The present invention exhibits such superior effects as described below. (1) The possibility that operation of a take-up unit is recovered without waiting processing of an operator is high, and the working efficiency of the take-up unit can be improved. (2) Since re-stopping does not occur in most cases after automatic re-starting, the frequency in which an operator goes to the site is reduced. The frequency in which the operator goes to the site for processing every time is reduced, and the labor is reduced. (3) Since a yarn supply bobbin is not abandoned but a remaining yarn is used, the yarn finely spun is taken up without waste. In other words, the yield in fine spinning is improved.

Claims: A method of taking up a yarn from a yarn supply bobbin (24) onto a package (25) and detecting (28, 10, 4) a defect of the yarn and cutting, joining (29) and taking up the yarn, when the number of times of detection of a defect within a predetermined amount of the yarn (Y) by such detection exceeds a present number of times taking up is stopped characterized in that that after taking up stopped the yarn of the yarn supply bobbin (24) is removed and abandoned over a certain length, and then the yarn on the yarn supply bobbin side and the yarn on the take-up package side are joined with each other and taking up is re-started. A method as claimed in claim 1, wherein the detection of a defect is performed by means of a slub catcher (28) provided on a yarn passage, and cutting of the yarn is performed compulsorily when a defect is detected. A method as claimed in claim 1 or 2, wherein the detection of a defect is based on the number of yarn break times. A method as claimed in one claims 1 to 3, wherein taking up is stopped when the number of times of detection of a defect reaches a number of times set for a unit length of the yarn. A method as claimed in one of claims 1 to 3, wherein taking up is stopped when the number of times of detection of a defect reaches a number of times set for a unit time. A method as claimed in one of claims 1 to 5, wherein removal of the yarn of the yarn supply bobbin is performed by a yarn sucking section (T) provided on a yarn passage. A method as claimed in claim 6, wherein removal of the yarn by said yarn sucking section is perfomed intermittently. A method as claimed in one of claims 1 to 7, wherein, when a yarn break occurs within a predetermined time after taking up is re-started, taking up is stopped and an alarm is developed. An automatic winder, comprising take-up means (21) for taking up a yarn (Y) from a yarn supply bobbin (24) onto a package (25), defect detecting means (28, 10, 4) for detecting and cutting a defect of the yarn (Y), yarn joining means (29) for joining the yarn (Y), controlling means form controlling the operation of said take-up means (21) and said yarn joining means (29), and yarn removing means (T) for removing a certain length of the yarn (Y) from the yarn supply bobbin (24), wherein controlling the operation of the take-up means (21), said yarn joining means (29) and that yarn removing means (T) is performed by said controlling means in response to a result of detection by said detecting means (28, 10, 4), and wherein said controlling means controls so that, when the number of times of detection of a defect within a predetermined amount of the yarn (Y) by said detecting means (28, 10, 4) exceeds a preset number of times, said take-up means (21) stops its operation and then said removing means (T) removes the yarn (Y) of the yarn supply bobbin (24) for a predetermined time, whereafter the yarns (Y) of the yarn supply bobbin (24) and the take-up package (25) are joined with each other by said yarn joining means (29) and then operation of said take-up means (21) is re-started. An apparatus as claimed in claim 9, wherein said removing means (T) for the yarn (Y) of the yarn supply bobbin (24) is yarn sucking means (5) provided on a yarn passage. An apparatus as claimed in claim 10, wherein said sucking means (T) includes a suction pipe (5) having an opening (5a) opposing to said yarn passage, and a cover member (15) for opening and closing said opening (5a) of said suction pipe (5). An apparatus as claimed in one of claims 9 to 11, wherein the time for releasing and removing the yarn (Y) of the yarn supply bobbin (24) is set by a timer (4).

Inventors: YAMAMOTO ATSUSHI, YAMAMOTO, ATSUSHI
Applicants: MURATA MACHINERY LTD, MURATA KIKAI KABUSHIKI KAISHA
Application year: 1994
Main classification: B65H63
IPC codes: B65H67, D01H13, D01H15, B65H63